Single flanged end ball valve of unitary construction

ABSTRACT

A ball valve unit for shutting off the flow of fluids flowing in heating and plumbing systems. The ball valve unit includes a ball valve and a main section including a flange formed integrally with the main section. A chamber is formed in the main section for receiving the ball of the ball valve. The main section is made of brass in order to prevent galvanic action between ball valve unit and the heating/plumbing system.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 10/097,762, filed Mar. 14, 2002.

CROSS REFERENCE TO RELATED APPLICATIONS

This Patent Application claims priority from U.S. Provisional PatentApplication Serial No. 60/300,345, filed on Jun. 22, 2001 and U.S.Provisional Patent Application Serial No. 60/300,622, filed on Jun. 25,2001, the contents of which are incorporated herein by reference in itsentirety.

BACKGROUND

This invention relates generally to ball valves, and more particularlyto a flanged end ball valve of unitary construction.

Traditionally, a ball valve is used in plumbing and heating applicationsto shut off the flow of water or other fluid during replacement orrepair of an in-line appliance or piece of equipment, such as acirculating pump. As shown in FIG. 1, typically, a ball valve used in aplumbing and heating application includes a separate flange 2, aconventional ball valve 4, and a copper nipple 6 and copper adapter 8that connect the flange 2 to the conventional ball valve 4. The ballvalve 4 is attached to the plumbing or heating system with copper tubing10. The in-line appliance (not shown) is attached to the flange 2.Alternatively, an iron nipple 12 has been used to connect the flange 2to the ball valve 4, and a copper adapter 14 has been used to connectthe ball valve 4 to the copper tubing 10, as shown in FIG. 2.

As shown in FIGS. 1 and 2, in the conventional methods, there areseveral potential leak paths. Also, there are areas of galvanic actionbetween dissimilar metals. Further, installation of the flange, thenipples, and the adapters in this type of configuration is timeconsuming and expensive.

The conventional method shown in FIG. 3 includes an iron flange 16 thatincludes a screwdriver slot ball valve. The flange 16 is connected to asecond iron flange 18. A copper adapter 20 connects the iron flange 18to copper tubing 10. In this configuration, since the flange 18 is madeof iron, there is an area of galvanic action between the iron flange 18and the copper adapter 20. Also, there are several potential leak paths.Further, this configuration is complex, which increases the cost andinstallation time.

FIG. 4 shows another conventional configuration. This configurationincludes an iron flange 30 connected to a copper tube 32 via a copperadapter 34. In this conventional configuration, it is not possible toisolate an in-line appliance, thereby making repair and replacement ofthe in-line appliance burdensome. Also, there are several potential leakpaths. Further, there are areas of galvanic action between the copperadapter 34 and the iron flange 30.

SUMMARY OF THE INVENTION

The present invention provides a ball valve unit that reduces the costand time required to replace in-line appliances such as pumps.

The ball valve unit of the present invention also reduces the number ofjoints and flanges, thereby reducing the volume of the plumbing systemand the number of leakage paths.

Further, the present invention also provides a ball valve unit thatprevents the cracking of brittle iron flanges and prevents galvanicaction.

The present invention comprises a main section, a flange for connectingthe ball valve unit to an appliance, wherein the flange is integrallyformed with the main section, a ball valve, a chamber formed in the mainsection for accommodating the ball of the ball valve, and a handle foractuating the ball valve.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the present inventionwill be more fully understood from the following detailed description ofillustrative embodiments, taken in conjunction with the accompanyingdrawings in which:

FIG. 1 shows a first conventional system.

FIG. 2 shows a second conventional system.

FIG. 3 shows a third conventional system.

FIG. 4 shows a fourth conventional system.

FIGS. 5A and 5B show cross-sectional views of one embodiment of the ballvalve unit of the present invention.

FIGS. 6A and 6B show cross-section views of a second embodiment of theball valve unit of the present invention.

FIGS. 7A and 7B show a third embodiment of the ball valve unit of thepresent invention.

FIGS. 8A and 8B show a fourth embodiment of the ball valve unit of thepresent invention.

FIGS. 9A and 9B show a fifth embodiment of the ball valve unit of thepresent invention.

FIGS. 10A and 10B show a sixth embodiment of the ball valve unit of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 5A shows a cross-sectional view of one embodiment of the presentinvention. As shown in FIG. 5A, the single flanged ball valve unit,according to the present invention, is designated by reference number50. It comprises a handle nut 52, a washer 54, a stem 56, a ball 58, abody 60, a handle 62, a packing gland 64, seats 66, and a stem seal 68.The body 60 comprises a main section 70 and an end cap 72. The mainsection 70 includes a chamber 74 adapted to accommodate the ball 58 andseats 66, a stem hole 76 to receive the stem 56 and stem seal 68, and aflange 78 to be positioned juxtaposed an inline appliance or equipment,such as a circulating pump (not shown). The ball valve unit 50,preferably, is 600 PSI rated for use with water, oil or gas. The innerdiameter of the chamber 74 is substantially equal to the inner diameterof the end cap 72, thereby maximizing flow through the ball valve unit.FIG. 5B shows a side view of the flange 78.

The main section 70 and flange 78 are of unitary construction andpreferably made from cast or hot forged brass. Since plumbing andheating systems typically comprise brass or copper tubing, this preventsthe occurrence of electrolysis and galvanic action at the junction ofthe ball valve unit and the system tubing. Also, brass is a much softeralloy than traditional iron used for the flanges currently on the marketthat often crack when slightly over tightened.

The ball 58 is preferably made of Brass/Hard Chrome Plate and fitsbetween seats 66, preferably made from Teflon® or PTFE. The ball 58 isactuated with a blow-out proof stem 56 preferably made of Brass (ASTMB124-C37700). The ball 58 is actuated with a handle 62, preferably madeof stamped steel with a vinyl coating.

The stem 56 is sealed with a stem seal 68, preferably made from Teflon®or PTFE, and an adjustable packing gland 64, preferably Brass (ASTMB124-C37700).

The end cap 72, preferably Brass (ASTM B124-C37700), is a threaded NPT(National Pipe Thread) connection, a Sweat (copper tubing) connection ora PEX (Cross Link Polyethylene) connection. The end cap 72 can be ofvarying sizes such as ½″, ¾″, 1″, 1¼″, 1½″ and 2″. The end cap 72 can bean (NPT) ANSI BI.20.1 threaded end (½″-2″), an ANSI B16.18 solder end(½″-2″), or a PEX insert end (½″-1″).

When the ball valve unit is installed, the flange 78 is bolted to, forexample, an iron flange that is part of a circulating pump (not shown).A rubber gasket 82 (preferably made of neoprene) forms the seal betweenthe two flanges. The rubber gasket can be part of the flange 78 or thepump. The gasket stops two unlike metals from touching each other, thuseliminating galvanic action. Preferably, the flange 78 is substantiallyflat so that it will fit different size appliances. The flange 78 isconsistent in size to fit most manufacturers smaller sized circulatingpumps. A preferred length and thickness of the flange is 4⅛″ and ⅜″,respectively.

FIG. 6A shows a cross-section of a second embodiment of the ball valveunit of the present invention. The second embodiment is substantiallysimilar to the first embodiment. As shown in FIG. 6A, the secondembodiment includes a wing-shaped handle 90 to allow for easy actuationof the valve. FIG. 6B shows a side view of the flange 78.

FIGS. 7A and 7B show a third embodiment of the ball valve unit of thepresent invention. As shown in FIG. 7A, the ball valve unit 100 includessimilar components as the ball valve unit 50 of the first embodiment.Specifically, the ball valve unit 100 comprises, inter alia, ball valve102, main section 104, handle 106, end cap 108, and flange 110. Inaddition, the ball valve unit 100 includes a drain valve 120. The drainvalve 120 is used to drain the system in the vicinity of the ball valve102. The drain valve 120 comprises a ball valve 122 that is actuated bya handle 124. The ball valve 122 is housed in extension tubing 126 thatis fitted to the main section 104 of the ball valve unit 100. A hose(not shown) can be attached to the extension tubing for draining thesystem. The extension tubing 126 preferably is made from cast or hotforged brass.

FIGS. 8A and 8B show a fourth embodiment of the ball valve unit of thepresent invention. The fourth embodiment is substantially similar to thethird embodiment and includes a wing-shaped handle 200, as shown inFIGS. 8A and 8B.

FIGS. 9A and 9B show a fifth embodiment of the ball valve unit of thepresent invention. The fifth embodiment is substantially similar to thethird embodiment. In the fifth embodiment, the drain valve 120positioned between the flange 110 and ball valve 102, as shown in FIGS.9A and 9B.

FIGS. 10A and 10B show a sixth embodiment of the ball valve unit of thepresent invention. The sixth embodiment is substantially similar to thefifth embodiment and includes a wing-shaped handle 300.

The present invention, without the addition of any additionalcomponents, can be used to quickly and easily replace plumbingcomponents and appliances such as pumps. The appliance can be changed bysimply closing the ball valves and loosening bolts in the flanges oneach side of the appliance. The appliance will then drop out and a newone can be placed back in, thereby minimizing installation problems.

Further, because the ball valve is formed integral with the flange, thenumber of joints is reduced, thereby reducing the volume of the systemand the number of leak paths.

Although the invention has been described with respect to variousembodiments, it should be realized this invention is also capable of awide variety of further and other embodiments. For example, the handle62, 90, 106, 200, 300 can be a different type than those shown in FIGS.5A-10B. In addition to brass, the body 60 and main section 70 can bemade of any material that reduces galvanic action, for example, copper,PVC, or bronze. Also, in the embodiments shown in FIGS. 7A-10B, ableeder valve can be used in addition to, or in place of, the drainvalve.

What is claimed is:
 1. A ball valve unit comprising; a ball section,said ball section defining a stem chamber and a ball chamber, said stemchamber disposed adjacent to and extending outwardly from said ballchamber; a ball valve including a ball, said ball disposed completelywithin said ball chamber; a stem disposed within and extending outwardlyfrom said stem chamber and connected to said ball disposed within saidball chamber, an exposed portion of said stem extending beyond said stemchamber; a handle connected to said exposed portion of said stemdisposed within said stem chamber and connected to said ball, whereinactuation of said handle effects actuation of said ball for operatingsaid ball valve unit; a main section disposed separate from and adjacentto said ball section; a drain valve communicating with said mainsection; and a flange formed as a continuous portion of at least one ofsaid main section and said ball section, said ball section includingsaid stem chamber and said ball chamber, wherein said flange, said mainsection and said ball section including said stem chamber and said ballchamber being formed as a single piece formed of a rigid material. 2.The ball valve unit of claim 1, wherein said ball valve unit furtherincludes a gasket disposed adjacent to said flange for forming a sealbetween said flange and an appliance.
 3. The ball valve unit of claim 1,wherein said main section and said ball section are made of brass. 4.The ball valve unit of claim 1, further including an end cap attached toat least one of said main section and said ball section.
 5. The ballvalve unit of claim 4, wherein said main section and said end cap aremade of brass.
 6. The ball valve unit of claim 4, wherein an innerdiameter of said chamber is substantially equal to an inner diameter ofsaid end cap.
 7. The ball valve unit of claim 1, wherein an outsidesurface of said flange is substantially flat.
 8. The ball valve unit ofclaim 1, wherein said handle is wing-shaped.
 9. The ball valve unit ofclaim 1, wherein said drain valve is disposed between said flange andsaid ball valve.